Your Reliable Partner Thermax Limited Sustainability through lesser energy intensive Indian Steel Industry - Vivek Taneja Disclaimer : This presentation is for information purpose only and Thermax reserves the right to alter or change specifications without prior notice. All photos in this presentation are representative in purpose and to be used for reference only.
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Your Reliable Partner Thermax Limited
Sustainability through lesser energy intensive Indian Steel Industry
- Vivek Taneja
Disclaimer : This presentation is for information purpose only and Thermax reserves the right to alter or change specifications
without prior notice. All photos in this presentation are representative in purpose and to be used for reference only.
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Sources of useful Waste Heat & Gases
Why waste recovery
Options of steam utilization
Need for carbon reduction PAT scheme
A word about us
Contents
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Sources of waste heat and gas
• Waste Heat
– Sponge Iron Kilns
– Non recovery Coke oven batteries
• Gas
– Blast furnace
– Recovery based Coke Ovens
– Corex Gas + dust
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Why Waste Heat Recovery ?
• Steam thereby Power / heating Cooling is incidental!!
• Environmentally – Clean and Green option.
• Cost of Power can be as Low as Rs 0.80 per Unit!!
• 100 TPD (DRI) Kiln can generate 1.6 MW of usable power i.e. 11 million units/year. Saving
per annum (Grid @ Rs. 2.5/kWh) is Rs. 22 Million/ Yr
• All the wastes from Sponge Iron Plant is used !!
- Waste Gases generated produce steam which generates power.
- Waste Like Coal Fines & Char - generate power in FBC Boiler.
- 100 TPD Kiln can generate another 1.5 MW of power using this waste.
- Saving another Rs. 20 -21 million/year
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• Potential in Coke ovens is even larger
– 75,000 MTPA - 6 MWe
– 150,000 MTPA - 12 MWe
– 300,000 MTPA - 24 MWe
– 600,000 MTPA - 48 MWe
• Potential from Blast furnace
– 250 m3/Hr – 5-6 MWe
– 500 m3/ Hr - 10-12 MWe
• Potential from recovery based coke ovens
– 1MTPA – 120MWe
Why Waste Heat Recovery ?
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Options for steam usage
LP Steam for Deaerator LP Steam for Boiler water pre heating
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Options for steam usage
Condenser
Cooling
chamber
Generator
Elevator
Heat recovery boiler
Cokes transfer car
Conveyor
Fan
Dust collector
Steam produced
Cokes basket
Steam turbine
Extracted
steam
Cokes
Hot coke
Condenser
Cooling
chamber
Generator
Elevator
Heat recovery boiler
Cokes transfer car
Conveyor
Fan
Dust collector
Steam produced
Cokes basket
Steam turbine
Extracted
steam
Cokes
Hot coke
WHR
Boiler
STG Gen
From Existing Coal
Based Boiler
Steam
Injection
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Options for steam usage
Application: To reduce the Coke Oven Gas Temperature
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Cogeneration
Trigeneration
ABSORPTION
CHILLER
CHILLING
UPTO 5 0C / (-)
30 0C
COOLING WATER HEAT
REJECTION AT 35 TO 40 0C
TO
PROCESS
HEATING
HRSG
STEAM
EXHAUST
GAS FROM
GT/DG STEAM/
HOT
WATER
EXHAUST
GAS
(TO STACK)
HRSG
Heat
Generator
Components – Power/ process side
• Gas Turbine
• DRI Kiln
• Coke oven Batteries
• IC Engine
Components – Recovery side
• HRSG / EGB
• Absorption Chiller
• Rankine Cycle Power Plant
Options for steam usage
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Need to reduce carbon - PAT
• India has made a commitment to global community to be a responsible
global citizen and reduce it carbon intensity.
• BEE has instituted a Perform Achieve & Trade (PAT) scheme for energy
intensive industry
• Steel is identified as a main Designated Consumer (DC) to reduce carbon &
energy intensity.
– The industry now has obligation to reduce the energy intensity
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• Captive power generation is a great success in industry and makes these
plants self sufficient.
• Continuous plant availability makes these plants highly reliable and profitable.
• Surplus power can be exported / certificates traded– separate revenue stream
• Coal fines & Char can be burnt in the FBC boiler for additional power generation,
taking care of environment issues as well as bringing extra revenue.
• Environment hazard is avoided as high temp gases are not vented out and most
process waste is utilized.
•Meets PAT targets and improves bottomlines
Advantages to industry
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• Understanding of the Process.
– Gas flow fluctuations
– Temperature variations
• Maximum & Minimum temperatures for corresponding gas flows
• Super heater design
• Attemperator selection
• Optimum point of operation for Boiler
– Start up procedures
– Batch process or continuous process
• Exhaust Gas composition
• Exhaust gas characteristics
• Nature of Dust
– Properties of Dust, Erosive/Corrosive
– Sticky/Free Flow
– Particle size distribution
Critical issues to be addressed for Waste Heat Boiler design
• Boiler Operating Parameters
- Optimum operating point for
boiler design
- Superheater design
- Type of attemperator
- Water quality
• Past experience of operation
- Field proven Calculation
programs
- Experience on Similar
applications
- Experience on the same
application
- Leanings in the past.
- Improvement done on the
process side.
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Boiler- Salient Features
• WHRB on CDQ key parameters to look for:
Experience in waste heat recovery in
coke oven plant
Water wall panel construction in 1st/2nd
pass for optimized heat X’fer
Gas tight membrane panel construction
Wide pitched in-line geometry to prevent
choking
On-line soot blowing system
Welded steel gill design of the
economizer for making the unit compact
• WHRB on Flue gas from Non-Recovery Type
Natural circulation design.
Gas tight membrane panel
construction
Wide pitched in-line geometry to
prevent choking.
On-line soot blowing system.
Two pass design
Radiation cavity to take care of
temperature excursions.
Optional blast furnace firing capability
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Other waste - Usage
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Ash and slag Problem
Half Solution
Problem shifted
from here to…
HERE
1st link of problem
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Options…
Potential uses :-
Fly Ash Bricks Classified Ash for Concrete Concrete blocks & Pavers AAC Blocks Pre-Stressed Concrete Ready Mix Mortar Rendering Material Special Cement Admixture
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Fully Automatic Vibro Compacting Technology for Concrete Product
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Details
Brick / hr 1,000 1,500 2,000 7,000
Working hr/day 10 10 10 21
Brick / day 10,000 15,000 20,000 147,000
Working Day/year 200 200 200 350
Brick / Year 2,000,000 3,000,000 4,000,000 51,450,000
Boilers & Heaters Cooling & Heating Power Generation Chemicals & Water Air Pollution Control
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Services Group - Operations and Maintenance, Steam on Hire, Renovation & Modernization,…
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• Contracted over 100 Power Projects in India and Abroad on turnkey basis including total BOP
• Over 3000 MW Projects already commissioned. Another 1050 MW under commissioning.
• Series of Bullet bonus for early completion of turnkey projects.
• O&M contracts for Power Projects representing over 1000MW
• Over 850,000 Hours of operational & maintenance experience.
• Boilers supplied produce steam equivalent to over 10,000 MW worldwide.
• Over 6000 Environment abatement systems working
• Can undertake complete mechanical , electrical BOP for utility Power plants on EPC basis
A word about us
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Conclusion
Sponge iron industry/ Steel facing tough challenges due to -
• Increased cost of Iron Ore And Coal.
• Coal Supply issues
• Campaign against illegal mining of Iron Ore In Some States.
• Many Companies have incurred losses in the past few months.
With Waste Heat Recovery and Power generation options the recovery
time on initial investments takes lesser time.
Meet PAT targets and improve profitability
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Case 1 - Sree Metaliks Limited 8 MW + 20 MW Captive Power Plant
• Based on 4 x 100 TPD + 1x 350 TPD Sponge Iron Kilns 350
• Location : Barbil, Orissa
• Scope: EPC including :
Design and Engineering of the entire plant
4 x 9.6 + 1 x 38 TPH Waste Heat Boilers with ESP
1 x 8 MW Condensing Turbine of + 20 MW STG BHEL make
DM Plant with all tankages and pipings
Cooling water, Air Compressor , Ventilation Sys, Piping etc.
Complete Civil Works with STG & Control Room Building
Electrical system & PC-PLC based Control system
Erection & Commissioning of the entire plant
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Sree Metaliks (P) Ltd.
Highlights:
- 28 MW of Power from Waste Heat Power Plant
- The 8 MW units was the first CPP in India to be set up in the sponge iron industry on EPC Basis. This is based on recovery of waste heat from the sponge iron kilns
Profile of some of our Power Projects
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BF Gas Based Project
Steel Authority of India, 42.5 MW, Rourkela, Orissa, India